Acoustic structural building panels

ABSTRACT

Described herein is an acoustic structural panel having a first exposed major surface opposite a second exposed major surface and side surfaces extending between the first and second exposed major surfaces, the acoustic structural panel comprising a first protective layer comprising at least a portion of the first exposed major surface, a second protective layer comprising at least a portion of the second exposed surface, a core structure located between the first and second protective layers, the core structure comprising, a foam body; and a fibrous body, wherein the first major exposed surface of the acoustic structural panel comprises a plurality of apertures exposing the fibrous body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/503,541, filed on May 9, 2017. The disclosure of the aboveapplication is incorporated herein by reference.

BRIEF SUMMARY

According to some embodiments, the present invention an acousticstructural panel having a first exposed major surface opposite a secondexposed major surface and side surfaces extending between the first andsecond exposed major surfaces, the acoustic structural panel comprisinga first protective layer comprising at least a portion of the firstexposed major surface; a second protective layer comprising at least aportion of the second exposed surface; a core structure located betweenthe first and second protective layers, the core structure comprising afoam body; and a fibrous body; wherein the first major exposed surfaceof the acoustic structural panel comprises a plurality of aperturesexposing the fibrous body.

In other embodiments, the present invention is directed to an acousticstructural panel having a first exposed major surface opposite a secondexposed major surface and side surfaces extending between the first andsecond exposed major surfaces, the acoustic structural panel comprising:a first protective layer comprising at least a portion of the firstexposed major surface; a second protective layer comprising at least aportion of the second exposed surface; a core structure located betweenthe first and second protective layers, the core structure comprising afirst body having a first major surface opposite a second major surface,whereby the first body does not allow for airflow between the first andsecond major surfaces of the first body under normal atmosphericconditions; and a second body having a first major surface opposite asecond major surface, whereby the second body allows for airflow betweenthe first and second major surfaces of the second body under normalatmospheric conditions; wherein the first major exposed surface of theacoustic structural panel comprises a plurality of apertures adjacent tothe second body.

In other embodiments, an acoustic structure system comprising a firstacoustic structural panel and a second acoustic structural panel, eachof the first and second acoustic structural panels having a firstexposed major surface opposite a second exposed major surface and sidesurfaces extending between the first and second exposed major surfaces,and each of the acoustic structural panels comprising: a firstprotective layer comprising a plurality of apertures; a secondprotective layer; and a core structure comprising a foam body and afibrous body, the core structure located between the first and secondprotective layers; wherein the side surfaces of the first acousticstructural panel comprise a first side surface having a firstinterlocking profile and the side surfaces of the second acousticstructural panel comprise a second side surface having a secondinterlocking profile, wherein the first interlocking profile iscomplimentary to the second interlocking profile; and wherein the firstacoustic structural panel and the second acoustic structural panel arejoined together by the first interlocking profile engaging the secondinterlocking profile.

According to other embodiments, the present invention a method ofinstalling an acoustic structure system comprising a) providing a firstacoustic structural panel and a second acoustic structural panel, eachof the first and second acoustic structural panels having a firstexposed major surface opposite a second exposed major surface and sidesurfaces extending between the first and second exposed major surfaces,and each of the acoustic structural panels comprising: a firstprotective layer comprising a plurality of apertures; a secondprotective layer; and a core structure comprising a foam body and afibrous body, the core structure located between the first and secondprotective layers; wherein the side surfaces of the first acousticstructural panel comprise a first side surface having a firstinterlocking profile and the side surfaces of the second acousticstructural panel comprise a second side surface having a secondinterlocking profile, wherein the first interlocking profile iscomplimentary to the second interlocking profile; and b) positioning thefirst acoustic structural panel adjacent to the second acousticstructural panel such that the first protective layer of the firstacoustic structural panel and the first protective layer of the secondacoustic structural panel fact the same direction; c) mating the firstinterlocking profile of the first acoustic structural panel with thesecond interlocking profile of the second acoustic structural panel.

Other embodiments of the present invention include an acoustic structurecomprising an acoustic enclosure formed from a plurality of acousticstructural panels each having a first exposed major surface opposite asecond exposed major surface and side surfaces extending between thefirst and second exposed major surfaces, each of the acoustic structuralpanels further comprising: a first protective layer comprising at leasta portion of the first exposed major surface, a second protective layercomprising at least a portion of the second exposed surface, a corestructure located between the first and second protective layers, thecore structure comprising: a foam body; and a fibrous body; wherein thefirst major exposed surface of the acoustic structural panel comprises aplurality of apertures exposing the fibrous body; wherein the pluralityof acoustic structural panels are coupled together to form at least aportion of the acoustic enclosure, the acoustic enclosure surrounding acavity and the first exposed major surfaces of each acoustic structuralpanel facing the cavity.

In other embodiments, the present invention includes an acoustic wallcomprising a first support a second support a plurality of acousticstructural panels positioned between the first and second supports, eachof the acoustic structural panels having a first exposed major surfaceopposite a second exposed major surface and side surfaces extendingbetween the first and second exposed major surfaces, the acousticstructural panel comprising: a first protective layer comprising atleast a portion of the first exposed major surface; a second protectivelayer comprising at least a portion of the second exposed surface; acore structure located between the first and second protective layers,the core structure comprising: a foam body; and a fibrous body; whereinthe first major exposed surface of the acoustic structural panelcomprises a plurality of apertures exposing the fibrous body.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a front perspective view of an acoustic structural panelaccording to the present invention;

FIG. 2 is a front view of the acoustic structural panel according to thepresent invention;

FIG. 3 is a rear view of the acoustic structural panel according to thepresent invention;

FIG. 4 is a side view of the acoustic structural panel according to thepresent invention;

FIG. 5 is a side view of the acoustic structural panel according to thepresent invention;

FIG. 6 is a front perspective view of an acoustic structure systemaccording to the present invention;

FIG. 6A is a close-up side view of the acoustic structure system shownin FIG. 6;

FIG. 7 is a cross-sectional view of the acoustic structural panel alongline VII-VII as set forth in FIG. 1;

FIG. 8 is an exploded view of the acoustic structural panel according tothe present invention;

FIG. 8A is a front perspective view of the acoustic structural panelaccording to another embodiment of the present invention;

FIG. 8B is an exploded view of the acoustic structural panel accordingto FIG. 8A;

FIG. 9 is a close-up perspective view of an acoustic structure systemaccording to another embodiment of the present invention in an unlockedstate;

FIG. 9A is a close-up view of an acoustic structure system of FIG. 9 ina locked state;

FIG. 10A is an exploded close-up view of an enclosure of region XA ofFIG. 21 comprising the acoustic structural panels according to thepresent invention in a locked-state;

FIG. 10B is an exploded close-up view of an enclosure comprising theacoustic structural panels according to the present invention;

FIG. 11 is a rear perspective view of an acoustic wall according toanother embodiment of the present invention;

FIG. 12 is a front perspective view of the acoustic wall of FIG. 11;

FIG. 13 is a rear view of the acoustic wall of FIG. 11;

FIG. 14 is a close-up view of region XIV of FIG. 13;

FIG. 15 is a top view of the acoustic wall of FIG. 11;

FIG. 16 is a front perspective view of an acoustic wall according toanother embodiment of the present invention;

FIG. 17 is a front perspective view of an acoustic wall according toanother embodiment of the present invention;

FIG. 18 is a rear perspective view of an acoustic wall according to FIG.17;

FIG. 19 is rear view of the acoustic wall according to FIG. 17;

FIG. 20 is a top view of the acoustic wall of FIG. 17;

FIG. 21 is a top perspective view of an acoustic enclosure according toanother embodiment of the present invention—including an explodedportion revealing the interior of an acoustic panel;

FIG. 22 is a close-up view of the acoustic enclosure according to FIG.21;

FIG. 23 is a close-up view of the acoustic enclosure according to FIG.21 with an access door removed;

FIG. 24 is a side view of the acoustic enclosure according to FIG. 21;

FIG. 25 is a cross-sectional view of the enclosure along line XXIV-XXIVof FIG. 24;

FIG. 26 is a top view of the acoustic enclosure according to FIG. 21including an exploded portion of a single middle building panel;

FIG. 27 is a cross-sectional view of the enclosure along lineXXVII-XXVII of FIG. 26;

FIG. 28 is a top perspective view of an acoustic enclosure according toanother embodiment of the present invention—including an explodedportion revealing the interior of an acoustic panel;

FIG. 29 is a top perspective view of an acoustic enclosure according toanother embodiment of the present invention—including an explodedportion revealing the interior of an acoustic panel;

FIG. 30 is a top perspective view of an acoustic enclosure of FIG. 29;

FIG. 31 is a cross-sectional view of the acoustic enclosure along lineXXXI-XXXI of FIG. 30;

FIG. 32 is front perspective view of an acoustic structural panelaccording to another embodiment of the present invention;

FIG. 33 is rear view of the acoustic structural panel according to FIG.32;

FIG. 34 is side view of the acoustic structural panel according to FIG.32;

FIG. 35 is front view of the acoustic structural panel according to FIG.32;

FIG. 36 is front perspective view of an acoustic structural panelaccording to another embodiment of the present invention;

FIG. 37 is rear view of the acoustic structural panel according to FIG.36;

FIG. 38 is side view of the acoustic structural panel according to FIG.36;

FIG. 39 is front view of the acoustic structural panel according to FIG.36;

FIG. 40 is an exploded perspective view of the acoustic structural panelof FIG. 36;

FIG. 41 is front perspective view of an acoustic structural panelaccording to another embodiment of the present invention;

FIG. 42 is rear view of the acoustic structural panel according to FIG.41;

FIG. 43 is front view of the acoustic structural panel according to FIG.41;

FIG. 44A is side view of the acoustic structural panel according to FIG.41;

FIG. 44B is cross-sectional view the acoustic structural panel accordingto FIG. 43 along line XLIVB-XLIVB;

FIG. 44C is close-up cross-sectional view of region XLIVC of FIG. 44B;and

FIG. 45 is perspective exploded view the acoustic structural panelaccording to FIG. 41.

DETAILED DESCRIPTION

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

As used throughout, ranges are used as shorthand for describing each andevery value that is within the range. Any value within the range can beselected as the terminus of the range. In addition, all references citedherein are hereby incorporated by referenced in their entireties. In theevent of a conflict in a definition in the present disclosure and thatof a cited reference, the present disclosure controls.

Unless otherwise specified, all percentages and amounts expressed hereinand elsewhere in the specification should be understood to refer topercentages by weight. The amounts given are based on the active weightof the material.

The description of illustrative embodiments according to principles ofthe present invention is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. In the description of embodiments of the inventiondisclosed herein, any reference to direction or orientation is merelyintended for convenience of description and is not intended in any wayto limit the scope of the present invention. Relative terms such as“lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,”“down,” “top,” and “bottom” as well as derivatives thereof (e.g.,“horizontally,” “downwardly,” “upwardly,” etc.) should be construed torefer to the orientation as then described or as shown in the drawingunder discussion. These relative terms are for convenience ofdescription only and do not require that the apparatus be constructed oroperated in a particular orientation unless explicitly indicated assuch.

Terms such as “attached,” “affixed,” “connected,” “coupled,”“interconnected,” and similar refer to a relationship wherein structuresare secured or attached to one another either directly or indirectlythrough intervening structures, as well as both movable or rigidattachments or relationships, unless expressly described otherwise.Moreover, the features and benefits of the invention are illustrated byreference to the exemplified embodiments. Accordingly, the inventionexpressly should not be limited to such exemplary embodimentsillustrating some possible non-limiting combination of features that mayexist alone or in other combinations of features; the scope of theinvention being defined by the claims appended hereto.

Unless otherwise specified, all percentages and amounts expressed hereinand elsewhere in the specification should be understood to refer topercentages by weight. The amounts given are based on the active weightof the material. According to the present application, the term “about”means +/−5% of the reference value. According to the presentapplication, the term “substantially free” less than about 0.1 wt. %based on the total of the referenced value.

Referring to FIGS. 1-5, the present invention is directed to an acousticstructural panel 10 (also referred to as “building panel”) that exhibitsboth acoustical performance and structural properties that allow it toserve a dual purpose as a sound attenuating panel as well as structuralelement in a building structure—as discussed further herein.

The building panel 10 of the present invention may comprise a firstexposed major surface 11 opposite a second exposed major surface 12 anda side surface 20 extending there-between. The side surface 20 maycomprise a first side surface 21 opposite a second side surface 22 and athird side surface 23 opposite a fourth side surface 24. The first andsecond side surfaces 21, 22 may be substantially parallel to each other.According to the present invention, the term “substantially parallel”refers to an angle that is 0°±2° as measured between the two referencedsurfaces. The third and fourth side surfaces 23, 24 may be parallel toeach other.

The first side and second side surfaces 21, 22 may each independentlyintersect both the third and fourth side surface 23, 24. The third andfourth side surfaces 23, 24 may each independently intersect both thefirst and second side surface 21, 22. The third and fourth side surfaces23, 24 may extend at an angle that is substantially perpendicular to thefirst and second side surface 21, 22. According to the presentinvention, the phrase “substantially perpendicular” refers to an anglethat is 90°±2° as measured between the two referenced surfaces. Thephrase “substantially orthogonal” may be used in place of “substantiallyperpendicular.”

The building panel may extend longitudinally along a longitudinal axisA-A that intersects the third and fourth side edges 23, 24. The buildingpanel may extend laterally along a lateral axis B-B that intersects thefirst and second side edges 21, 22.

As discussed further herein, the building panel 10 may be verticallyoriented such that the longitudinal axis A-A of the building panel 10extends normal to a ground surface. In such vertical orientation, thefirst side surface 21 may be a first vertical side surface 21 and thesecond side surface 22 being a second vertical side surface. In suchembodiments, the third side surface 23 may be an upper side surface 23and the fourth side surface 24 may be a lower side surface.

As discussed further herein, the building panel 10 may be verticallyoriented such that the lateral axis B-B of the building panel 10 extendsnormal to a ground surface. In such horizontal orientation, the firstside surface 21 may be a lower side surface 21 and the second sidesurface 22 being an upper side surface. In such embodiments, the thirdside surface 23 may be a first vertical side surface 23 and the fourthside surface 24 may be a second vertical side surface.

The building panel 10 may have a panel width W_(P) as measured by thedistance between the first and second side surfaces 21, 22 in adirection that is substantially perpendicular to the longitudinal axisA-A. The panel width W_(P) may range from about 10 inches to about 50inches—including all distances and sub-ranges there-between. Thebuilding panel 10 may have a panel length L_(P) as measured by thedistance between the third and fourth side surfaces 23, 24 in adirection that is substantially parallel to the longitudinal axis A-A.The panel length L_(P) may range from about 4 feet to about 24feet—including all distances and sub-ranges there-between. In apreferred embodiment, the panel length L_(P) may range from about 8 feetto about 14 feet—including all distances and sub-ranges there-between.

A ratio of the panel length L_(P) to panel width W_(P) may range fromabout 1.8:1.0 to about 17.0:1.0-including all ratios and sub-rangesthere-between. In a preferred embodiment, the ratio of the panel lengthL_(P) to panel width W_(P) may range from about 1.8:1.0 to about4.0:1.0—including all ratios and sub-ranges there-between.

The building panel 10 may have a panel thickness t_(P) as measured bythe distance between the first exposed major surface 11 and the secondexposed major surface 12. The panel thickness t_(P) may range from about2 inches to about 7 inches—including all distances and sub-rangesthere-between. In a preferred embodiment, the panel thickness t_(P) mayrange from about 2 inches to about 5 inches—including all distances andsub-ranges there-between.

A ratio of the panel length L_(P) to panel thickness t_(P) may rangefrom about 72.0:1.0 to about 12.0:1.0-including all ratios andsub-ranges there-between. In a preferred embodiment, the ratio of thepanel length L_(P) to panel width W_(P) may range from about 42.0:1.0 toabout 20.0:1.0-including all ratios and sub-ranges there-between. Aratio of the panel width W_(P) to panel thickness t_(P) may range fromabout 36.0:1.0 to about 6.0:1.0-including all ratios and sub-rangesthere-between. In a preferred embodiment, the ratio of the panel lengthL_(P) to panel width W_(P) may range from about 22.0:1.0 to about10.0:1.0-including all ratios and sub-ranges there-between. In apreferred embodiment, a ratio of the panel length L_(P) to panel widthW_(P) to panel thickness t_(P) may range from about 48.0:23.0:1 to about24.0:12.0:1.0-including all ratios and sub-ranges there-between.

The first exposed major surface 11 may have a first surface area asmeasured by the area that occupies the space between the side surfaces20 on the first exposed major surface 11. The first exposed majorsurface 11 may comprise a vented portion 30 comprising a plurality ofvent apertures 31 (also referred to as “holes” or “ports”)—as describedfurther herein. The vented portion 30 is perforated, thereby forming adiscontinuous surface portion of the first exposed major surface 11,wherein the discontinuous nature is the result of the present of theplurality of vent apertures 31.

The first exposed major surface 11 may also comprise a perimeter portion40 that at least partially circumscribed the vented portion 30 on thefirst major surface. The perimeter portion 40 may be continuous. Theterm “continuous” refers a surface being non-perforated andsubstantially free of open apertures. A surface may be continuous andcomprise one or more apertures so long as such apertures are masked oroccupied—for example, an aperture containing a fastener or connectionhardware therein, as discussed in greater detail herein.

The vented portion 30 may be about 30% to about 99% of the first surfacearea of the first exposed major surface 11—including all percentages andsub-ranges there-between. The perimeter portion 40 may be about 1% toabout 70% of the first surface area of the first exposed major surface11—including all percentages and sub-ranges there-between.

The building panels 10 may comprise one or more interlocking profiles50. Referring now to FIGS. 5, 6 and 6A, the side surfaces 20 maycomprise an interlocking profile 50 (also referred to herein as an“interlocking geometry”). The term “interlocking profile” refers tosurface geometry forming complimentary shapes that facilitate thecoupling together a plurality of the building panels 10 to form anacoustic structural panel system 1 (also referred to herein as a “panelsystem” 1).

Non-limiting examples of interlocking profiles 50 include tongue andgroove, shiplap, dovetail, mortise and tenon, butt joint, and the like.Each building panel 10 may comprise the interlocking profile 50 on thefirst exposed major surface 11, the side surface 20, as well ascombinations thereof so that an array and/or combination of buildingpanels 10 can be positioned adjacent to each other to form a continuouswall or housing—as discussed in greater detail herein.

Referring now to FIG. 5, for a single acoustic panel 10, the first sidesurface 21 may comprise a first interlocking profile 51 and the secondside surface 22 may comprise a second interlocking profile 52, wherebythe first and second interlocking profiles 51, 52 complement each other.In a non-limiting example, the first interlocking profile 51 of thefirst side surface 21 may comprise a groove 70 and the secondinterlocking profile 52 of the second side surface 22 may comprise atongue 60 that is complimentary in shape to the groove 70 of the firstinterlocking profile.

The groove 70 may comprise a groove floor 71 and groove walls 72. Thegroove floor 71 may be inset on the first side surface 21. The tongue 60may be a flange having a flange face 61 located between flange walls 62.The flange face 61 may protrude outward on the second side surface 22.

Referring now to FIGS. 6 and 6A, the panel system 1 of the presentinvention may comprise a plurality of building panels 10. Specifically,the system 1 may comprise at least a first building panel 10 a and asecond building panel 10. The first and second building panels 10 a, 10b are like the previously discussed the building panel 10, and thedescription of the building panel 10 above generally applies to thefirst and second building panels 10 a, 10 b described below except thata letter suffix of a, b, c, d . . . etc., will be used to differentiateeach individual of the plurality of building panels.

In a non-limiting example, the first and second building panels 10 a, 10b may each have a first interlocking profile 51 a, 51 b on the firstside surface 21 a, 21 b that comprises a groove 70 a, 70 b and a secondinterlocking profile 52 a, 52 b on the second side surface 22 a, 22 bthat comprises a tongue 60 a, 60 b that is complimentary in shape to thegroove 70 a, 70 b of the first interlocking profile 51 a, 51 b. Underthis configuration a first and second building panels 10 a, 10 b may bepositioned adjacent to each other such that the groove 70 b of the firstinterlocking profile 51 b of the first side surface 21 b of the secondbuilding panel 10 b mates with the tongue 70 a of the secondinterlocking profile 52 a of the second side surface 22 a of the firstbuilding panel 10 a, to create a continuous acoustic structural wall.

The panel system 1 may comprise the first side surface 21 a of the firstbuilding panel 10 a at least partially abutting and making directcontact with the second side surface 22 b of the second building panel10 b. Under such configuration, the groove floor 71 a of the firstbuilding panel 10 a may mate with and contact the flange face 61 b ofthe second building panel 10 b. Under such configuration, the groovewalls 72 a of the first building panel 10 a may also mate with andcontact the flange walls 62 b of the second building panel 10 b.

Once mated together, the first exposed major surface 11 a of the firstbuilding panel 10 a and the first exposed major surface 11 b of thesecond building panel 10 b may combine to make a front major surface 2of the panel system 1. Similarly, the second exposed major surface 12 aof the first building panel 10 a and the second exposed major surface 12b of the second building panel 10 b may combine to make a rear majorsurface 3 of the panel system 1. At least a portion of the side surface20 of the first building panel 10 a and the side surface 20 of thesecond building panel 10 b may combine to make a perimeter edge 4 of thepanel system 1.

Each of the side surfaces 20 of the building panel 10 may furthercomprise a gasket that form a seal between adjacent building panels. Thegasket may be formed from a polymeric material. Non-limiting examples ofpolymeric material include PVC, polytetrafluorothylene (“PTFE”), rubber,thermoplastic elastomer (“TPE”). For adjacent building panels 10positioned adjacent to each other, the gasket present on the sidesurface 20 may help forma moisture and/or air-tight seal there-between.

According to the present invention, the building panel 10 of the presentinvention is self-support and exhibit strength sufficient for aself-supporting structure to be formed from only one or more of thebuilding panels 10 used in combination. As discussed further herein, thebuilding panel 10 may exhibit sufficient strength for a self-supportingstructure to be formed, whereby the first exposed major surface 11 ofthe building panel 10 forms the interior surface of an enclosure and thesecond exposed major surface 12 of the building panel 10 forms theexterior surface of the enclosure.

Referring now to FIGS. 7 and 8, the building panel 10 of the presentinvention may be formed from a combination of materials that, together,provide the sound attenuation and structural integrity that allow thebuilding panel 10 to function as the acoustic and structural panel.Specifically, the building panel 10 may be formed from a shell 100 and acore structure, the core structure formed from a foam layer 200, and afibrous layer 300.

The shell 100 may comprise a chamber 110 formed by a first protectivelayer 120, a second protective layer 130. Each of the first protectivelayer 120 and second major layer 130 may be formed from a metal,ceramic, composite material (e.g., polymer and ceramic), or otherinorganic materials such as fiberglass, and combinations thereof. In anon-limiting embodiment, the metal may be steel, stainless steel,aluminum, aluminum-zinc alloy (also referred to as “galvalume”),aluminum-zinc alloy coated sheet steel metal, galvanized tin, andcombinations thereof. In some embodiments, the shell 100 may furthercomprise and anti-microbial coating.

The shell 100 may comprise an outer surface 101 opposite an innersurface 102. The shell 100 may have a shell thickness t₁ as measured bythe distance between the outer surface 101 and the inner surface 102.The shell thickness t₁ may range from about 15 mils to about 150mils—including all distances and sub-ranges there-between.

The first protective layer 120 may have an outer surface opposite aninner surface 122. The first protective layer 120 may have a thicknessas measured between the outer and inner surfaces 121, 122 that issubstantially equal to the shell thickness t₁. The first protectivelayer 120 may comprise a first major surface 123 opposite a second majorsurface 124. The first major surface 123 of the first protective layer120 may form at least a portion of the outer surface 121 of the firstprotective layer 120. The second major surface 124 of the firstprotective layer 120 may form at least a portion of the inner surface122 of the first protective layer 120. The first major surface 123 ofthe first protective layer 120 may form at least a portion of the firstexposed major surface 11 of the building panel 10. The outer surface 121of the first protective layer 120 may form at least a portion of thefirst exposed major surface 11 of the building panel 10.

The first protective layer 120 may comprise a first lip 141 that isopposite a second lip 145 across the longitudinal axis A-A. The firstlip 141 of the first protective layer 120 may be located toward a firstedge of the first protective layer 120 proximate to the first sidesurface 21 of the building panel 10, and the second lip 145 of the firstprotective layer 120 may be located toward a second edge of the firstprotective layer 120 proximate to the second side surface 22 of thebuilding panel 10.

The first lip 141 of the first protective layer 120 may extend from thesecond major surface 124 of the first protective layer 120 in adirection toward the second protective layer 130. Specifically, thefirst lip 141 of the first protective layer 120 may extend substantiallyperpendicular to the second major surface 124 of the first protectivelayer 120, whereby a plane extending along the longitudinal axis A-A andthe lateral axis B-B intersects both the first lip 141 and the foam body200.

The first lip 141 of the first protective layer 120 may comprise anouter surface 142 opposite an inner surface 143, wherein the outersurface 121 of the first protective layer 120 comprises the outersurface 142 of the first lip 141. The inner surface 122 of the firstprotective layer 120 may comprise the inner surface 143 of the first lip141 of the first protective layer 120. The outer surface 142 of thefirst lip 141 of the first protective layer 120 may extend substantiallyperpendicular to the first major surface 123 of the first protectivelayer 120. The outer surface 142 of the first lip 141 of the firstprotective layer 120 may form at least a portion of the first sidesurface 21 of the building panel 10.

The second lip 145 of the first protective layer 120 may extend from thesecond major surface 124 of the first protective layer 120 in adirection toward the second protective layer 130. Specifically, thesecond lip 145 of the first protective layer 120 may extendsubstantially perpendicular to the second major surface 124 of the firstprotective layer 120, whereby a plane extending along the longitudinalaxis A-A and the lateral axis B-B intersects both the second lip 145 andthe foam body 200.

The second lip 145 of the first protective layer 120 may comprise anouter surface 146 opposite an inner surface 147, wherein the outersurface 121 of the first protective layer 120 comprises the outersurface 146 of the second lip 142 of the first protective layer 120. Theinner surface 122 of the first protective layer 120 may comprise theinner surface 147 of the second lip 145 of the first protective layer120. The outer surface 146 of the second lip 145 of the first protectivelayer 120 may extend substantially perpendicular to the first majorsurface 123 of the first protective layer 120. The outer surface 146 ofthe second lip 145 of the first protective layer 120 may form at least aportion of the second side surface 22 of the building panel 10.

The first protective layer 120 may comprise a central region 180 that iscircumscribed by a perimeter region 190. The central region 180 of thefirst protective layer 120 may form the vented portion 30 of thebuilding panel 10 and the perimeter region 190 of the first protectivelayer 120 may form the perimeter portion 40 of the building panel 10.The central region 180 comprises an outer surface 181 that is oppositean inner surface 182, and the perimeter region 190 comprises an outersurface 191 that is opposite an inner surface 192. The outer surface 181of the central region 180 may form at least a portion of the outersurface 121 of the first protective layer 120. The inner surface 182 ofthe central region 180 may form at least a portion of the inner surface122 of the first protective layer 120. The outer surface 191 of theperimeter region 190 may form at least a portion of the outer surface121 of the first protective layer 120. The inner surface 192 of theperimeter region 190 may form at least a portion of the inner surface122 of the first protective layer 120.

The apertures 30 of the building panel 10 may be formed into the centralregion 180 of the first protective layer 120, whereby the aperturesextend continuously from the inner surface 182 to the outer surface 181of the central region 180 of the first protective layer 120. Theperimeter region 190 of the first protective layer 190 may besubstantially free of perforations and/or open apertures.

The central region 180 and the perimeter region 190 may be formed from asingular sheet of material, whereby the central region 180 is formed bypunching perforations to form the apertures 30. In another embodiment,the central region 180 may be formed from a first sheet of material andthe perimeter region 190 may be formed from a second sheet of material,whereby the first sheet of material forming the central region 180 issecured to building panel 10 by one or more fasteners 170 and/orsurrounds. In a non-limiting example, the fastener 170 maybe a strip ofL-shaped trim, T-shaped trim, Z-shaped trim, or the like. In suchembodiments, the fastener 170 may be removable such that the sheetforming the central region 180 may be removed from the building panel10.

The second protective layer 130 may have an outer surface 131 oppositean inner surface 132. The second protective layer 130 may have athickness as measured between the outer and inner surfaces 131, 132 thatis substantially equal to the shell thickness t₁. The second protectivelayer 130 may comprise a first major surface 133 opposite a second majorsurface 134. The first major surface 133 of the second protective layer130 may form at least a portion of the outer surface 131 of the secondprotective layer 130. The second major surface 134 of the secondprotective layer 130 may form at least a portion of the inner surface132 of the second protective layer 130. The first major surface 133 ofthe second protective layer 130 may form at least a portion of thesecond exposed major surface 12 of the building panel 10. The outersurface 131 of the second protective layer 130 may form at least aportion of the second exposed major surface 12 of the building panel 10.

The second protective layer 130 may comprise a first lip 151 that isopposite a second lip 155 across the longitudinal axis A-A. The firstlip 151 of the second protective layer 130 may be located toward a firstedge of the second protective layer 130 proximate to the first sidesurface 21 of the building panel 10, and the second lip 155 of thesecond protective layer 130 may be located toward a second edge of thesecond protective layer 130 proximate to the second side surface 22 ofthe building panel 10.

The first lip 151 of the second protective layer 130 may extend from thesecond major surface 134 of the second protective layer 130 in adirection toward the first protective layer 120. Specifically, the firstlip 141 of the second protective layer 130 may extend substantiallyperpendicular to the second major surface 134 of the second protectivelayer 130, whereby a plane extending along the longitudinal axis A-A andthe lateral axis B-B intersects both the first lip 151 of the secondprotective layer 130 and the foam body 200.

The first lip 151 of the second protective layer 130 may comprise anouter surface 152 opposite an inner surface 153, wherein the outersurface 131 of the second protective layer 130 comprises the outersurface 152 of the second lip 151. The inner surface 132 of the secondprotective layer 130 may comprise the inner surface 153 of the first lip151 of the second protective layer 130. The outer surface 152 of thefirst lip 151 of the second protective layer 130 may extendsubstantially perpendicular to the first major surface 133 of the secondprotective layer 130. The outer surface 152 of the first lip 151 of thesecond protective layer 130 may form at least a portion of the firstside surface 21 of the building panel 10.

The second lip 155 of the second protective layer 130 may extend fromthe second major surface 134 of the second protective layer 130 in adirection towards the first protective layer 120. Specifically, thesecond lip 155 of the second protective layer 130 may extendsubstantially perpendicular to the second major surface 134 of thesecond protective layer 130, whereby a plane extending along thelongitudinal axis A-A and the lateral axis B-B intersects both thesecond lip 155 of the second protective layer 130 and the foam body 200.

The second lip 155 of the second protective layer 130 may comprise anouter surface 156 opposite an inner surface 157, wherein the outersurface 131 of the second protective layer 130 comprises the outersurface 156 of the second lip 155 of the second protective layer 130.The inner surface 132 of the second protective layer 130 may comprisethe inner surface 157 of the second lip 152 of the second protectivelayer 130. The outer surface 156 of the second lip 155 may extendsubstantially perpendicular to the first major surface 133 of the secondprotective layer 130. The outer surface 156 of the second lip 155 mayform at least a portion of the second side surface 22 of the buildingpanel 10.

The first lip 141 of the first protective layer 120 and the first lip151 of the second protective layer 130 may extend toward each other. Thesecond lip 145 of the first protective layer 120 and the second lip 155of the second protective layer 130 may extend toward each other.

The foam layer 200 may form a foam body that is located within thechamber 110 formed by the shell 100. The foam body may comprise a firstmajor surface 201 opposite a second major surface 202 and a side surface203 extending there-between. The foam layer 200 may have a foamthickness t₂ as measured by the distance between the first major surface201 and the second major surface 202. The foam thickness t₂ may rangefrom about 1 inch to about 6 inches—including all distances andsub-ranges there-between. In a preferred embodiment, the foam thicknesst₂ may range from about 1 inch to about 4 inches—including all distancesand sub-ranges there-between.

The foam body of the foam layer 200 may further comprise a depression210 that is formed into the first major surface 201 of the foam body.The depression extends from the first major surface 201 to a depressionfloor 211 along a direction moving from the first major surface 201 tothe second major surface 202. The depression 210 may also be referred toas an “open cavity” 210 that is formed into the first major surface 201of the foam body 200, whereby the cavity floor 211 may also be referredto as a “cavity floor” 211.

The depression 210 may be circumscribed by an upstanding wall 212 formedby the foam body. The depression 210 may extend to a depression depth t₃as measured by the distance between the first major surface 201 of thefoam body of the foam layer 200 and the depression floor 211 of the foamlayer 200. The depression depth t₃ may range from about 0.5 inches toabout 4.5 inches—including all distances and sub-ranges there-between.In a preferred embodiment, the depression depth t3 may range from about1 inch to about 2 inches—including all distances and sub-rangesthere-between. The portion of the foam layer 200 present between thesecond major surface 202 and the depression floor 210 may be a reducedthickness t₄ ranging from about 0.5 to about 3.5-including all distancesand sub-ranges there-between. In a preferred embodiment, the reducedthickness t₄ may range from about 2 inches to about 3 inches—includingall distances and sub-ranges there-between.

A ratio between the depression depth t₃ and the foam thickness t₂ mayrange from about 0.2:1 to about 0.9:1-including all ratios andsub-ranges there-between.

The foam layer 200 may be formed from closed-celled foam. Theclose-celled foam does not allow for airflow between the first andsecond major surfaces of the first body under normal atmosphericconditions. The foam layer 200 may be formed from a foamable compositionthat is capable of being poured to shape in a mold, whereby the foamablecomposition then foams to form the closed-cell foam in the shape of thefoam layer 300. Non-limiting examples of suitable foam that may form thefoam layer 200 include urethane foam. The foam layer 200 may have asubstantially uniform density. The density of the foam layer 200 mayrange from about 0.5 lb/ft³ to about 6 lb/ft³—including all densitiesand sub-ranges there-between. In a preferred embodiment, the density ofthe foam layer 200 may range from about 0.5 lb/ft³ to about 4lb/ft³—including all densities and sub-ranges there-between.

The side surfaces 203 of the foam layer 200 may comprise a first sidesurface 221 opposite a second side surface 222 and a third side surface223 opposite a fourth side surface 24. The first and second sidesurfaces 221, 222 of the foam layer 200 may be substantially parallel toeach other. The third and fourth side surfaces 223, 224 of the foamlayer 200 may be parallel to each other.

The first side and second side surfaces 221, 222 of the foam layer 200may each independently intersect both the third and fourth side surface223, 224 of the foam layer 200. The third and fourth side surfaces 223,224 of the foam layer 200 may extend at an angle that is substantiallyperpendicular to the first and second side surface 221, 222 of the foamlayer 200.

The first side surface 21 of the building panel 10 may comprise at leasta portion of the first side surface 221 of the foam layer 200. Thesecond side surface 22 of the building panel 10 may comprise at least aportion of the second side surface 222 of the foam layer 200. The thirdside surface 23 of the building panel 10 may comprise at least a portionof the third side surface 223 of the foam layer 200. The fourth sidesurface 24 of the building panel 10 may comprise at least a portion ofthe fourth side surface 224 of the foam layer 200.

Specifically, the foam layer 200 may be formed such that the sidesurfaces 203 comprise edge geometry that conforms to the interlockingprofile 50 of the side surfaces 20 of the building panel 10.Specifically, each of the side surfaces 203 of the foam layer 200 may beformed such that the first, second, third, and/or fourth side surfaces221, 222, 223, 224 of the foam layer 200 comprise an edge geometry thatcorresponds to the interlocking profile 50 of each of the first, second,third, and/or fourth interlocking profiles 51, 52, 53, 54 of thebuilding panel 10.

In a non-limiting example, the first side surface 221 of the foam layer200 may be formed to comprise a groove 70 including the groove floor 71and groove walls 72. In another non-limiting example, the second sidesurface 222 of the foam layer 200 may be formed to comprise a tongue 60including the flange face 61 and the flange walls 62. In anothernon-limiting example, the third side surface 223 and the fourth sidesurface 224 of the foam layer 200 may each be formed to comprise eithera tongue 60 or groove 70. Therefore, the groove floor 71, groove walls72, flange face 61, and flange walls 62 may at least be partially formedby one or more of the closed-celled foam materials.

The fibrous layer 300 may form a fibrous body that is also locatedwithin the chamber 110 formed by the shell 100. The fibrous body maycomprise a first major surface 301 opposite a second major surface 302and a side surface 303 extending there-between. The fibrous layer 300may have a fibrous thickness as measured by the distance between thefirst major surface 301 and the second major surface 302 of the fibrouslayer 300. The fibrous thickness may be substantially equal to thedepression depth t₃ of the foam layer 200. In other embodiments, thefibrous thickness may be less than the depression depth t₃ of the foamlayer 200.

A ratio between the fibrous layer thickness and the foam thickness t₂may range from about 0.2:1 to about 0.9:1-including all ratios andsub-ranges there-between.

The fibrous layer 300 may be formed from a fibrous material.Non-limiting examples of fibrous material include inorganic fiber—suchas mineral wool (also referred to as slag wool), rock wool, stone wool,glass fibers, and combinations thereof. In some embodiments, the fibrouslayer 300 may further comprise a binder (e.g., polyurethane binder,epoxy binder, a latex), a filler (e.g., talc, calcium carbonate) and/oradditive (e.g., fungicide). The fibrous layer 300 may have asubstantially uniform density. The density of the fibrous layer 300 mayrange from about 3 lb/ft³ to about 10 lb/ft³—including all densities andsub-ranges there-between. In a preferred embodiment, the density of thefibrous layer 300 may range from about 4 lb/ft³ to about 8lb/ft³—including all densities and sub-ranges there-between.

The building panel 10 may be assembled such that the foam layer 200 andthe fibrous layer 300 are positioned between the first and secondprotective layers 120, 130. The second major surface 202 of the foamlayer 200 faces the inner surface 131 of the second protective layer130. Specifically, the second major surface 202 of the foam layer 200may face the second major surface 134 of the second protective layer130. An adhesive may be applied between the second major surface 202 ofthe foam layer 200 and the second major surface 134 of the secondprotective layer 130, thereby adhesively bonding the two surfacestogether. Non-limiting examples of adhesive include pressure sensitiveadhesive, hot-melt adhesive, epoxy, and combinations thereof.

The building panel 10 may be assembled such that a portion of the firstside surface 221 of the foam layer 200 faces the inner surface 153 ofthe first lip 151 of the second protective layer 130 and a portion ofthe second side surface 222 of the foam layer 200 faces the innersurface 157 of the second lip 155 of the second protective layer 130.Adhesive may be applied between the portion of the first side surface221 of the foam layer 200 and the inner surface 153 of the first lip 151and/or applied between the portion of the second side surface 222 of thefoam layer 200 and the inner surface 157 of the second lip 155, therebyadhesively bonding the surfaces together.

The building panel 10 may be assembled such that the first major surface201 of the foam layer 200 faces the inner surface 121 of the firstprotective layer 120 of the shell 100. An adhesive may be appliedbetween the first major surface 201 of the foam layer 200 and the innersurface 121 of the first protective layer 120 of the shell 100—therebyadhesively bonding the two surfaces together.

In particular, the building panel 10 may be assembled such that thefirst major surface 201 of the foam layer 200 faces the inner surface191 of the perimeter region 190 of the first protective layer 120 of theshell 100. An adhesive may be applied between the first major surface201 of the foam layer 200 and the inner surface 191 of perimeter region190 of the first protective layer 120 of the shell 100—therebyadhesively bonding the two surfaces together.

The fibrous layer 300 may sit within the depression 210 of the foamlayer 200 such that the second major surface 302 of the fibrous layer300 faces the depression floor 211 of the foam layer 200. In someembodiments, second major surface 302 of the fibrous layer 300 maydirectly contact the depression floor 211 of the foam layer 200.Although not pictured in FIG. 7, some embodiments of the presentinvention include one or more intermediate layers positioned between thesecond major surface 302 of the fibrous layer 300 and the depressionfloor 211 of the foam layer 200. Non-limiting examples of intermediatelayers include reinforcing layers.

The fibrous layer 300 may sit within the depression 210 of the foamlayer 200 such that the upstanding walls 212 of the foam layer 200 facethe side surfaces 303 of the fibrous layer 300. In some embodiments, theside surfaces 303 of the fibrous layer 300 may directly contact theupstanding walls 212 of the foam layer 200. In other embodiments, theupstanding walls 212 of the foam layer 200 and the side surfaces 303 ofthe fibrous layer 300 may be offset by one or more fasteners 170 orintermediate layers.

According to the present invention, the building panel 10 may beassembled such that the first major surface 301 of the fibrous layer 300faces the inner surface 121 of the first protective layer 120 of theshell 100. According to the present invention, the interface between thefirst major surface 301 of the fibrous layer 300 and the inner surface121 of the first protective layer 120 may be substantially free ofadhesive. The first major surface 301 of the fibrous layer 300 may be infree-floating contact with the inner surface 121 of the first protectivelayer 120.

In particular, the first major surface 301 of the fibrous layer 300 mayface the inner surface 181 of the central region 180 of the firstprotective layer 120 of the shell 100. According to the presentinvention, the interface between the first major surface 301 of thefibrous layer 300 and the inner surface 181 of the central region 180may be substantially free of adhesive. The first major surface 301 ofthe fibrous layer 300 may be in free-floating contact with the innersurface 181 of the central region.

Additionally, the fibrous layer 300 may sit within the depression 210 ofthe foam layer 200 such that the first major surface 301 of the fibrouslayer 300 and the first major surface 201 of the foam layer 200 face thesame direction. Specifically, the fibrous layer 300 may sit within theopen cavity 210 of the foam layer 200 such that the first major surface301 of the fibrous layer 300 and the first major surface 201 of the foamlayer 200 face the inner surface 122 of the first protective layer 120.The side surface 303 of the fibrous layer 300 may face the upstandingwall 212 of the foam layer 200.

Although not pictured, some embodiments of the present invention includeone or more intermediate layers may be positioned between secondprotective layer 130 and the second major surface 202 of the foam layer200. Although not pictured, some embodiments of the present inventioninclude one or more intermediate layers may be positioned between firstprotective layer 120 and the first major surface 201 of the foam layer200. Although not pictured, some embodiments of the present inventioninclude one or more intermediate layers may be positioned betweenupstanding walls 212 and/or cavity floor 211 and the second majorsurface 302 and/or side surface 303 of the fibrous layer 300. Theintermediate layers may be added to added structural integrity to theoverall building panel 10.

Non-limiting examples of material that may form the intermediate layermay include sheetrock, gypsum board, sheet metal, mass loaded vinyl, alaminated material (e.g., vinyl layers), polyvinylchloride (“PVC”),fiberglass, and combinations thereof. According to some embodiments, anadhesive may be applied between the intermediate layer and the adjacentlayer.

According to the present invention, the first major surface 11 of thebuilding panel 10 may comprise the first protective layer 120 of theshell 100. The second major surface 12 of the building panel 10 maycomprise the second protective layer 130 of the shell 100. The sidesurface 20 of the building panel 10 may comprise the side surface 140 ofthe shell 100. The side surface 20 of the building panel 10 may furthercomprise at least a portion of the side surface 203 of the foam layer200.

According to the present invention, the plurality of apertures 30 exposeat least a portion of the first major surface 301 of the fibrous layer300 to the first exposed major surface 11 of the building panel 10. Assuch, the building panel 10 may be formed from materials suitable forproviding mechanical strength for the building panel 10 to function as astructural panel (i.e., the shell 100 and foam layer 200) whilesimultaneously providing an exposed major surface 11 that exhibitsairflow characteristics suitable for the building panel to function as anoise reducing panel.

As discussed, the first protective layer 120 of the shell 100 maycomprise the vented portion 30 of the first major surface 11. The ventapertures 31 present on the vented portion 30 are open channels thatextend entirely between the inner and outer surface 121, 122 of thefirst protective layer 120. Under this configuration, at least a portionof the first major surface 301 of the fibrous layer 300 is directlyadjacent to the vented portion 30 of the first major surface 11 suchthat the plurality of vent apertures 31 are immediately adjacent to thefibrous layer 300. The result is the fibrous layer 300 being at leastpartially and directly exposed to the exterior environment thatsurrounds the building panel 10 via the vent apertures 31 present on thevented portion 30 of the first protective layer 120 of the shell 100.Under such configuration, the airflow directly into the building panel10—specifically directly into the fibrous layer 300—is possible for airmoving in a direction that extends from the first major surface 11 tothe second major surface 12 of the building panel 10.

Such airflow allows the building panel 10 to exhibit sound attenuationof a noise generating from a noise source when the building panel 10 ispositioned such that the first major surface 11 of the building panel 10is at least partially facing the noise source.

Sound attenuation is a characteristic of the building panel 10 thatrepresents the building panel's 10 ability to reduce the amount of soundon a specific side of the building panel 10—e.g., sound generated on thefirst majors side of the building panel 10. The sound reduction may beuseful in creating an enclosure environment that a specific level ofsound deadening is required. One measurement of the sound attentionability is the Noise Reduction Coefficient (NRC) rating as described inASTM test method C423. This rating is the average of sound absorptioncoefficients at four ⅓ octave bands (250, 500, 1000, and 2000 Hz),where, for example, a system having an NRC of 0.80 has about 80% of theabsorbing ability of an ideal absorber. A higher NRC value indicatesthat the material provides better sound absorption and reduced soundreflection. The building panel 10 of the present invention exhibits anNRC of at least 0.75, more specifically, at least 0.85. The buildingpanel 10 of the present invention exhibits an NRC of at least 0.9.

Sound attenuation of the building panel 10 may effectuated by the ventapertures 31 present on the vented portion 30 of the building panel 10.The vent apertures 31 may have a diameter ranging from about 62 mils toabout 300 mils—including all distances and sub-ranges there-between. Ina preferred embodiment, the vent apertures 31 present on the ventedportion 30 may have a diameter ranging from about 125 mils to about 190mils—including all distances and sub-ranges there-between.

The vent apertures 31 may be present on the vented portion 30 in afrequency such that the open area formed from the vent apertures 31occupy about 20% to about 60% of the total surface area of the ventedportion 30—including all amounts and sub-ranges there-between. In apreferred embodiment, the vent apertures 31 may be present in afrequency such that the open area formed from the vent apertures 31occupy about 30% to about 50% of the total surface area of the ventedportion 30—including all amounts and sub-ranges there-between.

Referring now to FIGS. 8A and 8B, the building panel of the presentinvention may further comprise a louvred cover 600. The louvred cover600 may comprise an array of inclined blades 602 offset by a pluralityof vented portions 602. The louvred cover 600 may be attached to theouter surface 121 of the first protective layer 120, thereby forming aportion of the first exposed major surface 11 of the building panel 10.The louvred cover 600 may be attached to the first protective layer 120by one or more fasteners 680.

The louvred cover 600 may be sized and positioned within the buildingpanel 10 such that the louvred cover 600 at least partially concealedthe central region 180 of the first protective layer 120 such that theinclined blades 602 at least partially masks the vented portion 30 ofthe building panel 10 in a vertical direction, thereby protecting theportions of fibrous layer 300 exposed via the vent apertures 30. Thevented portions 602 allow for sufficient airflow for the vented portion30 of the building panel 10 to still be able to receive and absorbairflow, thereby providing noise reducing to the surroundingenvironment.

Referring now to FIGS. 9, 9A, and 10, the building panels 10 of thepresent invention may further comprise a locking feature 400 present onat least one of the side surfaces 20 of the building panel 10. Thelocking feature 400 may be provided to prevent the two adjacent buildingpanels 10 from separating from each other once in an installedstate—i.e., a fully formed system 1. The locking feature 400 may bealtered between an unlocked state (as shown in FIG. 11) and a lockedstate (as shown in FIG. 12), whereby in the unlocked state a first andsecond building panel 10 a, 10 b, may be pulled apart relative to eachother. In a locked state, the first and second building panel 10 a, 10b, are coupled together by mechanical fastener that prevents relativemovement between the two. Non-limiting examples of the locking featureinclude cam hook and post fasteners.

In a non-limiting example, the locking feature 400 may comprise a firstlocking feature 410 and a second locking feature 420. The first lockingfeature 410 may be present on a first or second side surface 21, 22 ofthe building panel 10 and the second locking feature 420 may be presenton the opposite of the second or first side surface 22, 21 of the samebuilding panel 10. As discussed in greater detail herein, the firstlocking feature 410 may be present on a third or fourth side surface 23,24 of the building panel 10 and the second locking feature 420 may bepresent on the opposite of the fourth or third side surface 24, 23 ofthe same building panel 10. As discuss in greater detail herein, thefirst major exposed surface 11 of the building panel 10 may alsocomprise the locking feature 400. In some embodiments, the perimeterregion 40 of the first exposed major surface 11 may comprise the firstlocking feature 410. In some embodiments, the perimeter region 40 of thefirst exposed major surface 11 may comprise the second locking feature420.

In a non-limiting embodiment, the first locking feature 410 includesinclude a first housing 411 and a cam hook 415 (also referred to as a“latch” 415), the cam hook 415 at least partially located within thefirst housing 411. The first housing 411 surrounds a first open-endedcavity (also referred to a “first cavity”), whereby a first opening 413on the first housing 411 exposes the first cavity to the exterior of thefirst locking feature 410. The first housing 411 may be located insetfrom the first side surface 21 of the building panel 10, whereby thefirst opening 413 is substantially flush with the first side surface 21.

The cam hook 415 is located at least partially within the first cavity.The cam hook 415 is rotatable relative to the first housing 411.Specifically, the cam hook 415 may be rotatable about a locking axis D-Dsuch that the cam hook 415 may be located entirely within the firsthousing or at least a portion of the cam hook 415 may extend beyond thefirst opening 413 and be located external the first housing 410.Specifically, the cam hook 415 may comprise a hook portion 417 that canbe locked entirely within the first housing 410 or, when the cam hook415 is rotated about the locking axis D-D, the hook portion 417 islocated external the first housing 411.

In a non-limiting embodiment, the second locking feature 420 includes asecond housing 421 and a post fastener 425 (also referred to as a “pin”425), the post fastener 425 is located within the second housing 421.The second housing 421 surrounds a second open-ended cavity (alsoreferred to a “second cavity”), whereby a second opening 423 on thesecond housing 421 exposes the second cavity to the exterior of thesecond locking feature 420. The second housing 421 may be located insetfrom the second side surface 22 of the building panel 10, whereby thesecond opening 423 is substantially flush with the second side surface22.

The post fastener 425 is located entirely within the second cavity. Thepost fastener 425 is fixed relative to the second housing 421. The firstand second locking features 410, 420 may be arranged such that the postfastener 425 extends along a longitudinal axis that is arrange in asubstantially parallel orientation to the locking axis D-D of the firstlocking feature 410. The second housing 421 may be configured to receivethe hook portion 417 of the cam hook 415 via the second opening 423 ofthe second housing 421.

In a non-limiting example, a first and second building panels 10 a, 10b, may be placed adjacent to each other and the first side surface 21 bof the second building panel 10 b that comprises the second lockingfeature 420 b may abut the second side surface 22 a of the firstbuilding panel 10 a that comprises the first locking feature 410 a. Oncethe first and second side surfaces 21 b, 22 a of the first and secondbuilding panels 10 a, 10 b are abutted, the first and second lockingfeatures 410 a, 420 b may be altered from the unlocked state (as shownin FIG. 9) to the locked state (FIG. 9A), whereby the first and secondlocking features 410 a, 420 b are in mechanical engagement.

In the unlocked state, the hook portion 417 a of the first lockingfeature 410 a of the first building panel 10 a may be located entirelywithin the first housing 411 a of the first building panel 410 a. In theunlocked state, the hook portion 417 a may at least partially extendbeyond the first opening 413 a of the first locking features 410 a ofthe first building panel 10 a, thereby extending beyond the second sidesurface 22 a of the second building panel 10 b. In the unlocked state,the hook portion 417 a of the first locking features 410 a of the firstbuilding panel 10 a may be completely external the second housing 421 bof the second locking feature 420 b of the second building panel 10 b.In other embodiments, in the unlocked state, the hook portion 417 a ofthe first locking feature 420 a of the first building panel 10 a may belocated at least partially within the second housing 421 b of the secondlocking feature 420 b of the second building panel 10 b so long as thehook portion 417 a of the first locking feature 410 a of the firstbuilding panel 10 a does not pull against the post fastener 425 b of thesecond locking feature 420 b of the second building panel 10 b. In theunlocked state, the first building panel 10 a may be able to moverelative to the second building panel 10 b. Specifically, in theunlocked state, the first side surface 21 b of the second building panel10 b may be able to move relative to the second side surface 22 a of thefirst building panel 10 a.

In locked state, the hook portion 417 a of the first locking feature 410a of the first building panel 10 a may be located within the secondhousing 421 b of the second building panel 10 b. As such, in the lockedstate, the hook portion 417 a of the first locking feature 410 a of thefirst building panel 10 a may be external the first housing 411 a of thefirst locking feature 410 a of the first building panel 10 a. In thelocked state, the hook portion 417 a of the first locking feature 410 aof the first building panel 10 a may pull against the post fastener 425b of the second locking feature 420 b of the second building panel 10 b,thereby pulling together the adjacent interlocking profiles 50 of thefirst and second building panel 10 a, 10 b. In a non-limiting example,in the locked state, the hook portion 417 a of the first locking feature410 a of the first building panel 10 a may pull against the postfastener 425 b of the second locking feature 420 b of the secondbuilding panel 10 b, thereby bringing into contact the first sidesurface 21 b of the second building panel 10 b and the second sidesurface 22 a of the first building panel 10 a, thereby preventingrelative movement between the first and second building panels 10 a, 10b. Specifically, in the locked state, the first side surface 21 b of thesecond building panel 10 b may be prevented from moving relative to thesecond side surface 22 a of the first building panel 10 a.

The building panels 10 of the present invention may further comprise oneor more tool apertures 18. The tool apertures 18 are configured toreceive a tool that converts the locking feature 400 between thelocked-state and the unlocked-state. Specifically, the tool apertures 18may be configured to receive a tool that converts the first lockingfeature 410 between the locked-state and the unlocked-state by rotating(either directly or indirectly) the cam hook 415 about the locking axisD-D between the locked and unlocked states.

In a non-limiting embodiment, the tool apertures 18 may be located onthe first exposed major surface 11 of the building panel 10. In otherembodiments, the tool apertures 18 may be located on the second exposedmajor surface 11 of the building panel 10. The took apertures 18 may belocated entirely within the perimeter region 40 of the first exposedmajor surface 11 of the building panel 10.

In the locked state, the first lip 141 of the first protective layer 120of a first building panel 10 may be in abutting contact with the secondlip 145 of the first protective layer 120 of a second building panel. Inthe locked state, the first lip 151 of the second protective layer 130of a first building panel 10 may be in abutting contact with the secondlip 155 of the second protective layer 130 of a second building panel.

Although not pictured, in other embodiments, a gasket or other sealingmaterial may be located between the first and second lips of the firstand second adjacent building panels. In such embodiments, locking thefirst and second locking features 410, 420 together may compress thegasket or sealing material, thereby forming a water-tight seal betweenadjacent first and second building panels.

In the locked state, the flange face 61 of the foam layer 200 of a firstbuilding panel may be in abutting contact with the groove floor 71 of asecond building panel. In the locked state, the flange walls 62 of thefoam layer 200 of the first building panel may be in abutting contactwith the groove walls 72 of the second building panel.

Although not pictured, in other embodiments, a gasket or other sealingmaterial may be located between the groove floor 71 and flange face 61and/or between flange walls 62 and the groove walls 72. In suchembodiments, locking the first and second locking features 410, 420together may compress the gasket or sealing material, thereby forming awater-tight seal between adjacent first and second building panels.

The foregoing discussion of the first and second locking feature 410,420 was set forth with respect to side surfaces 20 of the adjacentbuilding panel 10—however, such discussion also applies to first andsecond locking features 410, 420 that may be located on the first and/orsecond exposed major surfaces 11, 12 of the building panel 10.

Referring now to FIGS. 11-16, the present invention further includes anacoustic wall 1000 comprising a plurality of the building panels 10 a,10 b, 10 c, 10 d, etc. in a vertically oriented configuration. Theacoustic wall 1000 of the present invention may comprise a verticalsupport 1600 comprising at least a first vertical support 1610 and asecond vertical support 1611. Non-limiting examples of the first andsecond vertical support 1610, 1611 include I-beams. Each of the firstand second vertical supports 1610, 1611 may comprise a base section 1601located at the bottom of each of the first and second vertical supports1610, 1611. In a non-limiting example, the base section 1601 may be aplate structure extending substantially perpendicular to the I-beam.

The acoustic wall 1000 includes at least a first building panel 10 a anda second building panel 10 b, whereby the second building panel 10 bsits atop the first building panel 10 a, thereby creating a verticallyoriented stack of first and second building panels 10 a, 10 b. Theacoustic wall 1000 may further comprise a third building panel 10 c, afourth building panel 10 d, and etc. arranged in the vertically stackedarrangement.

In a non-limiting example, the first and second sides 21, 22 of onebuilding panel 10 may contact the first and second sides 21, 22 of anadjacent vertically stacked building panel 10. In such arrangement, thethird and fourth sides 23, 24 may be located at least partially within achannel section formed by the first and second vertical supports 1610,1611. Under this arrangement, the third and fourth sides 23, 24 of thebuilding panels may be at least partially masked by the first and secondvertical supports 1610, 1611.

Each of the first major exposed surfaces 11 of the building panels mayface the same direction—i.e., a first direction. Each of the secondmajor exposed surfaces 12 of the building panels may face the samedirection—i.e., a second direction. According to the present invention,the first direction faces a noise source such that the vented portions30 of the first major exposed surfaces 11 may face the noise source,thereby helping to reduce the perceivable amount of sound when locatedadjacent to the second exposed major surface 12 as less sound maypenetrate through the wall and extend the second direction.Additionally, in having the vented portions 30 of the first majorexposed surfaces 11 face the noise source, the perceivable amount ofsound may also be reduced for an observed located adjacent to the firstexposed major surfaces 11, as the vented portion helps reduce the amountof sound that bounces back in the first direction.

Referring now to FIG. 16, the acoustic wall 1000 may be formed from aplurality of vertical supports 1610, 1611, 1612, 1613, whereby theacoustic wall 1000 further comprises a first vertical stack 1010 a of aplurality of building panel 10 and at least a second vertical stack 1010b of a plurality of building panels 10.

Referring now to FIGS. 13 and 14, the acoustic wall 1000 may be securedto into a ground 8 by one or more fasteners 1602 extending from the basesection 1601 of each vertical support 1610, 1611, 1612, 1613 into afoundation element 1605. The foundation element 1605 may be a pouredconcrete body, a steel body—such as a steel base.

Referring now to FIGS. 17-20, the present invention further includes anacoustic wall 2000 comprising a plurality of the building panels 10 a,10 b, 10 c, 10 d, etc. in a horizontally oriented configuration. Theacoustic wall 2000 of the present invention may comprise a verticalsupport 2600 comprising at least a first vertical support 2610 and asecond vertical support 2611. Non-limiting examples of the first andsecond vertical support 2610, 2611 include I-beams. Each of the firstand second vertical supports 2610, 2611 may comprise a base section 2601located at the bottom of each of the first and second vertical supports2610, 2611. In a non-limiting example, the base section 2601 may be aplate structure extending substantially perpendicular to the I-beam.

The acoustic wall 2000 includes at least a first building panel 10 a anda second building panel 10 b, whereby the second building panel 10 b atleast partially overlaps in a horizontal direction to the first buildingpanel 10 a, thereby creating a horizontally oriented array of first andsecond building panels 10 a, 10 b. The acoustic wall 2000 may furthercomprise a third building panel 10 c, a fourth building panel 10 d, andetc. arranged in the horizontally oriented array.

In a non-limiting example, the first and second sides 21, 22 of a firstbuilding panel may contact the first and second sides 21, 22 of anadjacent horizontally overlapping building panel 10. In sucharrangement, the third and fourth sides 23, 24 of each building panelmay extend between the first and second vertical supports 1610, 1611.

Each of the first major exposed surfaces 11 of the building panels mayface the same direction—i.e., a first direction. Each of the secondmajor exposed surfaces 12 of the building panels may face the samedirection—i.e., a second direction. According to the present invention,the first direction faces a noise source such that the vented portions30 of the first major exposed surfaces 11 may face the noise source,thereby helping to reduce the perceivable amount of sound when locatedadjacent to the second exposed major surface 12 as less sound maypenetrate through the wall and extend the second direction.Additionally, in having the vented portions 30 of the first majorexposed surfaces 11 face the noise source, the perceivable amount ofsound may also be reduced for an observed located adjacent to the firstexposed major surfaces 11, as the vented portion helps reduce the amountof sound that bounces back in the first direction.

Referring now to FIG. 18, the acoustic wall 2000 may further comprise ahorizontal support structure 2620 that extends horizontally and at leastpartial spans a first and second building panel 10 a, 10 b. Thehorizontal support structure 2620 may be a plate formed of metal,whereby the plate is secured to the second exposed major surface 12 ofthe building panels by one or more fasteners 2200. The horizontalsupport structure 2620 may also be secured to at least one of the firstand/or second vertical supports 2610, 2611.

The horizontal array acoustic wall 2000 may be secured to the ground 8in the same manner as previously described with respect to thevertically stacked acoustic wall 1000. In some embodiments, the acousticwall 2000 may further comprise a U-channel 2500 that at least partiallyspans the distance between the first and second vertical supports 2610,2611, whereby the fourth side surfaces (or third side surfaces) of eachbuilding panel 10 nests within the U-channel 2500 to help give theacoustic wall 2000 further support.

The acoustic walls 2000, 3000 according to the present invention maycomprise a louvred cover on the first exposed major surface 11 of thebuilding panels.

Referring now to FIGS. 21-27, the present invention further provides anacoustical enclosure 3000 formed from a plurality of building panels 10,10 i, 10 ii according to the present invention. In a non-limitingexample, the acoustical enclosure 3000 of the present invention may besuitable for fully or partially enclosing a noise generating device(e.g., a compressor, a generator, a pump, etc.) or may be suitable forcreating a climate-controlled enclosure (e.g., a walk-in freezer). Insuch embodiments, the first exposed major surfaces 11 of each buildingpanel 10, 10 i, 10 ii may face in the interior of the enclosure 3900(also referred to as an internal cavity 3900 of the enclosure), and thesecond exposed major surface 12 of each building panel 10 may form theexterior surface of the enclosure 3000.

The building panels 10 i and 10 ii used to form the enclosure areillustrated in accordance with another embodiment of the presentinvention. The building panels 10 i and 10 ii are similar to thebuilding panel 10 except as described herein below. The description ofthe building panel 10 above generally applies to the building panels 10i and 10 ii described below except with regard to the differencesspecifically noted below. A similar numbering scheme will be used forthe building panels 10 i and 10 ii as with the building panel 10 exceptthat the (i) and (ii) suffix will be used.

The acoustic enclosure 3000 of the present invention may be formed froma plurality of wall structures 3010 and a ceiling structure 3020. Theceiling structure 30210 may be coupled to the ceiling structure 3020

Each wall structure 3010 comprises a bottom portion 3011 and an upperportion 3012. Each wall structure 3010 may be formed by one or more ofthe building panels 10 coupled together in a locked state. The ceilingstructure 3020 may be formed by one or more of the building panels 10 i,10 ii coupled together in a locked state. The ceiling structure 3020comprises an upper face opposite a lower face 3021. The lower face 3021of the ceiling structure may mate with the upper portion 3012 of thewall structure 3010. The third and/or fourth sides of the buildingpanels 10 may at least partially form the upper and bottom portions3011, 3012 of the wall structure.

Referring now to FIGS. 28, 29, and 31, the acoustic enclosure 3000 mayfurther comprise one or more U-channels 3500. The U-channel 3500 mayhave a floor 3520 and two upstanding walls 3510 that define groove. Thebottom portions 3011 of the wall structures 3010 may be inserted intothe grooves of the U-channels 3500, thereby further stabilizing theacoustic enclosure 3000. One or more fasteners 3008 (e.g., bolt) may bedrilled through the underside of the U-channel floor 3520 into the foamlayer 200 of the building panel 10 to stabilize the building panel 10 inplace.

Although not pictured, in other embodiments, a gasket or other sealingmaterial may be located between the building panel 10 and the U-channel3500 to form a water-tight seal therebetween. The bottom portions 3011of the wall structure may also comprise an overhang extending out andbelow the upper edge of the upstanding wall of the U-channel, thereby todivert liquid away from the groove of the U-channel 3500/

Together, the wall structures 3010 and the ceiling structure 3020 definean internal cavity 3900, whereby the first exposed major surface 11, 11i, 11 ii of each building panel 10, 10 i, 10 ii faces the cavity 3900.The first exposed major surfaces 11 i, 11 ii of each building panel 10i, 10 ii may form the lower face 3021 of the ceiling structure 3020.According to the present invention one or more noise generating machinesmay be housed by the acoustic enclosure, whereby the noise generatingmachine is located in the cavity 3900 and surrounded by the wallstructures 3010 and the ceiling structure 3020.

Each of the acoustic wall structures may be connected together by acorner panel 90. The corner panels 90 may form an L-shaped verticalpanel have a first and second major edge configured to mate with one ofthe interlocking profiles 50 of the building panel 10.

The cavity 3900 may be accessible via one or more access panels 80 (alsoreferred to as an access door 80). The access panel 80 may be locatedbetween two building panels 10 or between a building panel 10 and acorner panel 90 (not pictured). The access panels 80 may comprisecontrol element 89 for a user to remove or install the access panel 80into the enclosure 3000. Non-limiting examples of control elements 89include a handle, a knob, a lever, a push bar, a pull bar, and the like.

The access panel 80 comprises an inner surface 82 that is opposite anouter surface 81 and a side surface 83 extending there-between. The sidesurface 83 of the access panel 80 may comprise an interlocking profile50 configured to mate with one of the interlocking profiles 50 of thebuilding panels 10 of the wall structure 3010 and/or the interlockingprofiles 50 i, 50 ii of the building panels 10 i, 10 ii of the ceilingstructure 3020. The access panel 80 may comprise a foam layer andfibrous layer as described with respect to the building panel 10 of thepresent invention. In other embodiments, the access panel may compriseonly the foam layer, whereby no fibrous layer is present in the accesspanel 80.

Referring now to FIGS. 24-27 and 32-40, the ceiling structure 3020 maybe formed from at least one end building panel 10 i and at least onemiddle building panel 10 ii.

Referring now to FIGS. 36-40 in particular, the middle building panel 10ii may comprise a plurality of interlocking profiles 50. Specifically,the side surfaces 20 ii of the middle building panel 10 ii may comprisea first interlocking profile 51 ii and a second interlocking profile 52ii that is arranged opposite from the first interlocking profile 51 ii.The first interlocking profile 51 ii and the second interlocking profile52 ii may be located on opposite sides of the longitudinal axis A-A ofthe middle building panel 10 ii. In the exemplified embodiment, thefirst and second interlocking profiles 51 ii, 52 ii are located on thefirst and second side surfaces of the middle building panel 10 ii.

In the exemplified embodiment, the middle building panel 10 ii may havethe first interlocking profile 51 ii may comprises a groove and thesecond locking feature 420 ii. In the exemplified embodiment, the secondinterlocking profile 52 ii may comprise a tongue and the first lockingfeature 410 ii. Under this configuration, a plurality of middle buildingpanels 10 ii may be coupled together in an array to form at least aportion of the ceiling structure 3020, whereby the second interlockingprofile 52 ii of a first middle building panel 10 ii is locked to thefirst interlocking profile 51 ii of a second middle building panel 10ii.

According to the present invention, the first and/or second sidesurfaces of the middle building panel 10 ii may each independentlycomprise a groove or a tongue as well as independently comprise thefirst or second locking feature 410 ii, 420 ii.

The difference in the middle building panel 10 ii as compared to thebuilding panel 10 of the previous embodiments is that the first majorexposed surface 11 ii may also comprise at least one interlockingprofile 50. In the exemplified embodiment, the first major exposedsurface 11 ii comprises a third interlocking profile 53 ii and a fourthinterlocking profile 54 ii. Specifically, the third and/or fourthinterlocking profiles 53 ii, 54 ii may be located on the first exposedmajor surface 11 ii of the middle building panel 10 ii adjacent to sidesurfaces 20 ii. The third interlocking profile 53 ii and the fourthinterlocking profile 54 ii may be located on opposite sides of thelateral axis B-B of the middle building panel 10 ii. According to thisembodiment, the third and/or fourth side surfaces may be formed by theshell 100—such as the second protective layer 130 of the shell 100. Thefirst and second side surfaces may be at least partially formed by thefoam layer 200.

In particular, the third interlocking profile 53 ii may be located onthe first exposed major surface 11 ii of the middle building panel 10 iiand intersect the first and second interlocking profiles 51 ii, 52 ii.The fourth interlocking profile 54 ii may be located on the firstexposed major surface 11 ii of the middle building panel 10 ii andintersect the first and second interlocking profiles 51 ii, 52 ii.

The first interlocking profile 51 ii may extend in the same direction asthe first side surface of the middle building panel 10 ii. The secondinterlocking profile 52 ii may extend in the same direction as thesecond side surface of the middle building panel 10 ii. The third andfourth interlocking profiles 53 ii, 54 ii may extend in the samedirection as the outer surface of the first protective layer 120 ii ofthe shell 100 ii.

In the exemplified embodiment, the third interlocking profile 53 ii maycomprises a groove and the second locking feature 420 ii. In theexemplified embodiment, the fourth interlocking profile 54 ii maycomprise a groove and the second locking feature 420 ii. Under thisconfiguration, the third side surfaces 23 of a plurality of verticallyoriented building panels 10, each of which comprise the third lockingprofile 53, may mate with the third and fourth interlocking profiles 53ii, 54 ii of the middle building panel 10 ii to support the ceilingstructure 3020 in the enclosure 3000—as demonstrated by FIGS. 25 and 27.Additionally, under this configuration, the first locking feature 410present on the third interlocking profile 53 of the third side surfaces23 of the vertically oriented building panels 10 may be interlocked withthe second locking features 420 ii of the middle building panels 10 ii.

With each of the middle building panels 10 ii spanning horizontallyacross opposite wall structures 3010, the core structure of the middlebuilding panel 10 ii may further comprise one or more reinforcingelements 700. Non-limiting examples of reinforcing elements 700 includemetal or composite bars extending longitudinally and having an I-beam,L-beam, or T-beam configuration). The reinforcing elements 700 mayextend within the middle building panels 10 ii in a direction that issubstantially parallel to the longitudinal axis. The reinforcingelements may extend through the foam layer 200 ii of the middle buildingpanels 10 ii.

Referring now to FIGS. 32-35 in particular, the end building panel 10 imay comprise a plurality of interlocking profiles 50. Like the middlebuilding panel 10 ii, the first major exposed surface 11 i of the endbuilding panel 10 i may also comprise at least one interlocking profile50. In the exemplified embodiment, the side surface 20 may comprise afirst interlocking profile 51 ii, whereby the first interlocking profile51 ii extends in a direction substantially parallel to the longitudinalaxis A-A of the end building panel 10 i.

In the exemplified embodiment, the first major exposed surface 11 icomprises a first interlocking profile 51 i, a third interlockingprofile 53 i, and a fourth interlocking profile 54 i. Specifically, thefirst interlocking profile 51 i, the third interlocking profile 53 i,and/or fourth interlocking profile 54 i may be located on the firstexposed major surface 11 i of the end building panel 10 i and adjacentto side surfaces 20 ii. The third interlocking profile 53 i and thefourth interlocking profile 54 i may be located on opposite sides of thelateral axis B-B of the middle building panel 10 ii. The first andsecond interlocking profiles 51 i, 52 i may be located on opposite sidesof the longitudinal axis A-A of the end building panel 10 i. Accordingto this embodiment, the first, third, and/or fourth side surfaces may beformed by the shell 100—such as the second protective layer 130 of theshell 100. The second side surface may be at least partially formed bythe foam layer 200.

In particular, the first interlocking profile 51 i may be located on thesecond side surface of the end building panel 10 i, the secondinterlocking profile 52 ii may be located on the first exposed majorsurface 11 i adjacent to the second side surface, the third interlockingprofile 53 i may be located on the first exposed major surface 11 iadjacent to the third side surface, and the fourth interlocking profile54 i may be located on the first major exposed surface 11 ii adjacent tothe fourth side surface. The third and fourth interlocking profiles 53i, 54 i may intersect the first and second interlocking profiles 51 i,52 i.

The first interlocking profile 51 i may extend in the same direction asthe first side surface of the middle building panel 10 i. The secondinterlocking profile 52 ii may extend in the same direction as the firstexposed major surface 11 i of the middle building panel 10 ii. Thefirst, third, and fourth interlocking profiles 51 i, 53 i, 54 i mayextend in the same direction as the outer surface of the firstprotective layer 120 i of the shell 100 i.

In the exemplified embodiment, the first interlocking profile 51 i maycomprise a groove and the second locking feature 420 i. In theexemplified embodiment, the third interlocking profile 53 i maycomprises a groove and the second locking feature 420 i. In theexemplified embodiment, the fourth interlocking profile 54 i maycomprise a groove and the second locking feature 420 i. Under thisconfiguration, the third side surfaces 23 of a plurality of verticallyoriented building panels 10, each of which comprise the third lockingprofile 53, may mate with the first, third, and fourth interlockingprofiles 51 i, 53 i, 54 i of the end building panel 10 i to support theceiling structure 3020 in the enclosure 3000. Additionally, under thisconfiguration, the first locking feature 410 present on the thirdinterlocking profile 53 of the third side surfaces 23 of the verticallyoriented building panels 10 may be interlocked with the second lockingfeatures 420 i of the end building panels 10 i.

Although not pictured, the enclosure 3000 may further include areinforcing structure that is located within the cavity 3900 andadjacent to the second exposed major surface 12 ii of the buildingpanels. In such embodiments, the reinforcing structure may form askeleton that supports the vertical and horizontally oriented buildingpanels that form the wall structure 3010 and ceiling structure 3020.

In the exemplified embodiment, the end panels 10 i may be coupled to theends of the array of middle building panels 10 ii, thereby forming acontinuous perimeter of locking profile on the lower face 3021 of theceiling structure 3020 of the enclosure—whereby the continuous perimetermates with the third side surfaces 53 of the vertically orientedbuilding panels 10 to form the enclosure 3000.

Referring now to FIGS. 29 and 30, the enclosure 3000 of the presentinvention may further comprise a roof structure 3800. The roof structure3800 may comprise a downward facing surface 3802 and an upward facingsurface 3801. The roof structure 3800 may be configured to be placedatop the ceiling structure 3020, thereby at least partially masking theupper face 3022 of the ceiling structure 3020. Specifically, the roofstructure may comprise a downward facing surface 3802 and an upwardfacing surface 3801, whereby in the installed state the downward facingsurface 3802 of the roof structure 3800 faces the upper face 3022 of theceiling structure 3020. The roof structure 3800 may be secured to theceiling structure 3020 by suitable fastener.

The roof structure 3800 may be formed from a single continuous body or acombination of panels coupled together to from a single structure. Theroof structure 3800 may be configured to have a sloped upward facingsurface 3801, thereby providing a surface that redirects rain water,snow, and other natural phenomena from resting atop the upward facingsurface 3801. Although not pictured, the roof structure 3800 may furthercomprise an overhang that extends beyond the second exposed majorsurface 12 of the vertical building panels 10. The overhang may alsoextend outward beyond the U-channel 3500. The roof structure 3800 alsoprotects one or more seams that may exist between adjacent ones of thebuilding panels 10 i, 10 ii that form the ceiling structure 3020.

Referring now to FIGS. 44-45, the present invention further provides abuilding panel 10 iii according to another embodiment of the presentinvention. The building panels 10 iii are similar to the building panel10 except as described herein below. The description of the buildingpanel 10 above generally applies to the building panels 10 iii describedbelow except with regard to the differences specifically noted below. Asimilar numbering scheme will be used for the building panels 10 iii aswith the building panel 10 except that the (iii) suffix will be used.

According to this embodiment of the present invention, the buildingpanel 10 iii comprises a shell 100 iii and a core structure comprisingonly the foam layer 200 iii. Stated otherwise, the core structure ofthis embodiment does not include a fibrous layer. Rather, the fibrouslayer 300 iii may be positioned external the shell 100 iii.Specifically, the second major surfaces 302 iii of the fibrous layer mayface the outer surface 101 iii of the shell 100 iii. Furthermore, asdemonstrated by FIGS. 42 and 45, the shell 100 iii comprises a first andsecond major surface that substantially free of perforations.

The fibrous layer 300 iii may be fixed within the building panel 10 iiiof this embodiment by a combination of a z-trim profile 95 iii and aperforated sheet 96 iii. The perforated sheet 96 iii may be the samethat makes up the central region 180 of the previous embodiments.Specifically, the perforated sheet 96 iii may comprise a plurality ofvent apertures 31 iii that form a vented portion 30 iii of the buildingpanel. The perforated sheet 96 iii may be placed into direct contactwith the first major surface 301 iii of the fibrous layer, whereby theperforated sheet 96 iii is fixed to the shell 100 iii by the z-trimprofile 95 iii and one or more fasteners.

Under this configuration, a standard non-acoustic panel comprising onlythe shell 100 iii and the foam layer 200 iii may be retrofitted with thefibrous layer 300, thereby rendering the previously non-acoustic panelto be an acoustic panel having a noise reducing surface 11 iii.

EXAMPLES Experiment 1

An acoustic structural panel according to the present invention wasprepared according to the following methodology. The shell was formedfrom aluminum zinc alloy coated sheet steel. The foam layer was formedfrom closed-celled urethane foam having a foam thickness t₂ of about 4inches. The fibrous layer was formed from mineral wool having a fibrousthickness of about 2 inches. The first major surface of the buildingpanel comprises vent apertures 31 having a diameter of about 125 mils ata frequency covering about 40% of the vented portion 30 of the firstmajor surface.

The resulting building panel had a panel length L_(P) of about 94inches, a panel width W_(P) of about 46 inches, and a panel thicknesst_(P) of about 4 inches. The overall building panel exhibited an areaweight of about 2.54 lb/ft² as measured along the first major surface ofthe building panel.

The building panel was positioned between two rooms: (1) a source roomhaving a total volume of 6,298 ft³ and (2) a receive room having totalvolume of 4,877 ft³. The first major surface of the building panel waspositioned such that it faced the (1) source room which contained anoise source, and the second major surface faced the (2) receive room.The noise source emitted a sound for a period of time, whereby the totalloss in sound—as measured in dB loss—as measured between the (1) sourceroom and the (2) receive room. The results are set forth below in Tables1 and 2.

TABLE 1 Freq. (Hz) 100 125 160 200 250 315 400 500 630 800 1k 1.25k 1.6k2k 2.5k 3.15k 4k 5k T.L. 23 19 19 18 19 21 23 26 27 30 34 37 35 34 44 5257 57 (dB)

As demonstrated by Table 1, the building panel performed exceptionallywell with respect to reducing sound in common frequency ranges—whichindicate that the building panel of the present invention would besuitable in a variety of applications that require sound-deadeningperformance.

TABLE 2 Freq. (Hz) 32 40 50 63 80 6.3k 8k 10k 12.5k T.L. 13 18 12 12 1459 61 59 53 (dB)

Additionally, as demonstrated by Table 2, the building panel alsoperformed exceptionally well as particularly high frequencies as welladequately at low frequencies, which indicate the building panel mayalso be suitable of for non-traditional sound-deadening applicationsthat relate to extreme high and/or low frequency noise generation.

Experiment 2

A second experiment was prepared using two acoustic structural panelsaccording to the present invention. Each building panel included a shellthat was formed from aluminum zinc alloy coated sheet steel. The foamlayer was formed from closed-celled urethane foam having a foamthickness t₂ of about 4 inches. The fibrous layer was formed frommineral wool having a fibrous thickness of about 2 inches. The firstmajor surface of the building panel comprises vents 31 having a diameterof about 125 mils at a frequency covering about 40% of the ventedportion 30 of the first major surface.

Each building panel had a panel length L_(P) of about 94 inches, a panelwidth W_(P) of about 46 inches, and a panel thickness t_(P) of about 4inches. Each building panel exhibited an area weight of about 2.52lb/ft² as measured along the first major surface of the building panel.The two building panels were placed adjacent to each other, whereby thelocking feature of each side surface was placed into a locked state. Theresulting wall formed from the combination of building panels had a walllength of about 94 inches, a wall width of about 93 inches, and a panelthickness t_(P) of about 4 inches.

The wall formed from the combination of building panels was positionedin a room environment having a total volume of 10,311 ft³ whereby thefront major surface 2 of the wall faced the room environment whichcontained a noise source. The noise source emitted a sound for a periodof time, whereby the NRC performance of the wall was measured. The wallexhibits an NRC performance of 0.90.

What is claimed is:
 1. An acoustic structural panel having a firstexposed major surface opposite a second exposed major surface and sidesurfaces extending between the first and second exposed major surfaces,the acoustic structural panel comprising: a first protective layercomprising at least a portion of the first exposed major surface, thefirst protective layer has an inner surface opposite an outer surface; asecond protective layer comprising at least a portion of the secondexposed surface; a core structure located between the first and secondprotective layers, the core structure comprising: a foam body having afirst major surface opposite a second major surface, side surfacesextending between the first and second major surfaces of the foam body,and a depression formed into the first major surface into the foam bodyand extends to a depression floor that is located between the first andsecond major surfaces of the foam body, and wherein the depression iscircumscribed by an upstanding wall that extends from the depressionfloor and intersects the first major surface of the foam body; and afibrous body located in the depression of the foam body, the fibrousbody comprises a first major surface opposite a second major surface anda side surface extending between the first and second major surfaces ofthe fibrous body, the first major surface of the fibrous body facing theinner surface of the first protective layer and the second major surfaceof the fibrous body facing the depression floor of the foam body; andwherein the first major surface of the fibrous body and the first majorsurface of the foam body face the same direction, and wherein the sidesurface of the fibrous body faces the upstanding wall of the foam body;and wherein the first major exposed surface of the acoustic structuralpanel comprises a plurality of apertures exposing the fibrous body, theplurality of apertures extending continuously from the inner surface tothe outer surface of the first protective layer.
 2. The acousticstructural panel according to claim 1, wherein fibrous body is locatedadjacent to the plurality of apertures.
 3. The acoustic structural panelaccording to claim 1, wherein the first protective layer has an innersurface opposite an outer surface, and wherein the apertures extendcontinuously from the inner surface to the outer surface of the firstprotective layer.
 4. The acoustic structural panel according to claim 1,wherein the second protective layer comprises an inner surface oppositean outer surface, the inner surface of the second protective layerfacing the second major surface of the foam body, wherein the outersurface of the second protective layer forms at least a portion of thesecond exposed surface of the acoustic structural panel, and wherein thesecond protective layer is non-perforated and substantially free of openapertures.
 5. The acoustic structural panel according to claim 1,wherein the foam body is a close-celled urethane foam.
 6. The acousticstructural panel according to claim 1, wherein the fibrous body compriseinorganic fiber selected from mineral wool, rock wool, stone wool, glassfibers, and combinations thereof.
 7. The acoustic structural panelaccording to claim 1, wherein the fibrous body exhibits an NRC value asmeasured between the first and second major surfaces that ranges fromabout 0.5 to about 0.95.
 8. The acoustic structural panel according toclaim 1, wherein the side surfaces comprise a first side surfaceopposite a second side surface, the first side surface comprises a firstinterlocking profile and the second side surface comprises a secondinterlocking profile, the first interlocking profile being complimentaryto the second interlocking profile.
 9. The acoustic structural panelaccording to claim 8, wherein the first interlocking profile is a grooveand the second interlocking profile is a tongue.
 10. The acousticstructural panel according to claim 8, wherein each of the firstinterlocking profile and the second interlocking profile are at leastpartially formed by the core structure.
 11. The acoustic structuralpanel according to claim 8, wherein the first side surface comprises afirst locking element and the second side surface comprises a secondlocking element, the first and second locking elements being configuredto interlock together.
 12. The acoustic structural panel according toclaim 11, wherein the first locking element comprises a pin locatedwithin a first housing and the second locking element comprises arotatable latch located within a second housing.
 13. The acousticstructural panel according to claim 12, wherein the first housing islocated inset from the first side surface and the second housing islocated inset of the second side surface.
 14. The acoustic structuralpanel according to claim 12, wherein the second locking element isconvertible from an unlocked-state to a locked-state, whereby in thelocked-state a hook portion of the latch protrudes beyond the secondside surface.
 15. The acoustic structural panel according to claim 1,wherein a first thickness is measured between the first major surfaceand the second major surface of the foam body, and a second thickness ismeasured between the first major surface of the foam body and thedepression floor, wherein a ratio of the second thickness and the firstthickness ranges from about 0.2:1 to about 0.9:1.
 16. The acousticstructural panel according to claim 15, wherein a third thickness ismeasured between the second major surface of the foam body and thedepression floor, the third thickness ranging from about 0.5 inches toabout 3.5 inches.
 17. An acoustic structural panel having a firstexposed major surface opposite a second exposed major surface and sidesurfaces extending between the first and second exposed major surfaces,the acoustic structural panel comprising: a first protective layercomprising at least a portion of the first exposed major surface; asecond protective layer comprising at least a portion of the secondexposed surface; a core structure located between the first and secondprotective layers, the core structure comprising a first body having afirst major surface opposite a second major surface, whereby the firstbody does not allow for airflow between the first and second majorsurfaces of the first body under normal atmospheric conditions; and asecond body having a first major surface opposite a second majorsurface, whereby the second body allows for airflow between the firstand second major surfaces of the second body under normal atmosphericconditions; wherein the first major exposed surface of the acousticstructural panel comprises a plurality of apertures adjacent to thesecond body; wherein the first major surface of the second body isadjacent to the first protective layer, and the second body is offsetfrom the second protective layer by a portion of the first body having athickness ranging from about 0.5 inches to about 3.5 inches.
 18. Theacoustic structural panel according to claim 17, wherein the second bodycomprises inorganic fiber.
 19. The acoustic structural panel accordingto claim 17, wherein the second body exhibits and NRC value of at least0.5 as measured between the first and second major surfaces of thesecond body.
 20. An acoustic structural panel having a first exposedmajor surface opposite a second exposed major surface and side surfacesextending between the first and second exposed major surfaces, theacoustic structural panel comprising: a first protective layercomprising at least a portion of the first exposed major surface; asecond protective layer comprising at least a portion of the secondexposed surface; a core structure located between the first and secondprotective layers, the core structure comprising: a foam bodycomprising: a first major surface opposite a second major surface; afirst thickness as measured between the first major surface and thesecond major surface of the foam body; a depression formed into thefirst major surface into the foam body and extending to a depressionfloor that is located between the first and second major surfaces of thefoam body; a second thickness as measured between the first majorsurface of the foam body and the depression floor; wherein a ratiobetween the second thickness and the first thickness ranges from about0.2:1 to about 0.9:1; and a fibrous body located in the depression ofthe foam body, the fibrous body comprises a first major surface oppositea second major surface, the first major surface of the fibrous bodyfacing the first protective layer and the second major surface of thefibrous body facing the depression floor of the foam body; and whereinthe first major exposed surface of the acoustic structural panelcomprises a plurality of apertures exposing the fibrous body.